KELLY & LEWIS

THE

"TRIUMPH"

MADE IN AUSTRALIA

TYPE H ENG. NO. 2814

B.H.P. 2  R.P.M. 600

Dalgety & Co. Sole Agent

   SYDNEY

The engine finished its 12000 mile trip from Melbourne Australia to Boston Massachusetts in June of 2006. 

Here's what was inside the crate - partially disassembled along with my Buzacott oil engine.  It didn't seem too bad, how soon I was proven wrong!

Intake valve guide was worn out and the valve seat pitted.  Here the old one is bored and reamed for a new bronze guide.

The new guide is drilled/reamed and valve seat faced on one setup.

Exhaust guide and seat get the same treatment only on the mill with right angle head.

Intake top hat casting was broken and the other piece was missing so I turned a new one from steel.

Here are all the bits and pieces I've got done so far.

The bore where butterfly valve seats is quite rough.  After much thought I decided the best things is to just bore it to clean.

.050 later the bore is straight, round and smooth again

Someone had taken a file to the flywheel bore and really did some damage.  The hole is not only oversize but also out of round and tapered.  End result is a flywheel that wobbles real bad!  Since my big Hendy lathe is not under power I have to clean up the bore on my mill.  Here I'm checking parallelism to both the spindle and table, both must be within .002

Now the rim is indicated to within .001 all around.

Taking the first cut - sure is uneven....

The bore finally cleaned up at .030 over

The original Lucas mag is in pretty good shape.  Here I'm cleaning up back of points case which was grooved and scored so the new brush will have a true surface to contact.

Boring the main and wrist pin bearings to size.

                One of the ears on my governor arm bracket was broken and welded back crooked.  Here I plunged thru with an end mill and reamed the new hole to size.  A length of drill rod was pressed in then it was                                    drilled and reamed back to original size.  The middle bit was cut out and ends filed to match the outside.

It's far easier the trace around bearing shims on the CNC mill than to fight with tin snips - especially in .002 316 stainless.

Milling the new magneto adapter base on a HAAS VF2.

I used Mastercam X2 to program the mill.  It did all the milling, drilling, tapping and chamfering to produce the finished part in 8 minutes!

New main bearings were made from cored bronze on a Dainichi F20 CNC lathe.

At some point the bearing boss was broken out and welded back in.

The boss wasn't welded back in straight meaning even more work for me.  Here the casting is indicated square to the table, it must be within .0005

The first cut, I'm using a solid carbide boring bar to cut down on chatter since the bore is over 4 inches deep.  .050 was removed to clean things up.

The side plate flange was not square to the crank either, .025 was removed and I shall now have to shim the plate by that much.